The three-year epidemic has had an immeasurable impact on the global economy, and the mainland cotton spinning industry has suffered multiple impacts higher than other industries, especially the extreme suppression of Xinjiang cotton by Western countries led by the United States, which has had a great impact on the product exports of mainland textile enterprises. But even in this case, the pace of intelligent upgrading and transformation of the mainland cotton spinning industry has not stagnated, but has made great achievements. The author briefly reviews the innovation and transformation process of intelligent cotton spinning production in the past three years, and finds the gaps, so as to continue to make efforts in difficult and hot projects.
First, the pace of development of intelligent manufacturing is accelerating
Due to historical reasons, as the world's largest textile producer, the overall level of intelligent equipment in the mainland cotton textile industry is not high, and there are many shortcomings, which have seriously restricted the process of modernization and development of the industry.
During the three-year epidemic period, the offline contact between enterprises has been significantly reduced, but online technical exchange activities have been popular, and the media such as China Yarn Network have continuously demonstrated the intelligent new technology developed by textile machinery in recent years to enterprises through live broadcast platforms, technical forums, special lectures, etc., setting off a climax of learning modern intelligent technology. The biggest advantage of this kind of exchange is that you can learn new technologies and recognize your own gaps.
At present, the intelligent level of mainland textile machinery is constantly improving, and many intelligent projects are originally developed by the mainland. From the automatic unpacking, transportation, packing, combing, and, coarse, fine to the automatic packaging and quality control of the package, the breadth, depth and difficulty involved are unprecedented, the mainland broke the monopoly, independently developed and designed some semi-automatic and fully automatic equipment in line with the national conditions of the mainland, such as the removal of cotton mulch film of high-efficiency foreign fiber machine, carding joint, thickness and fine winding, etc., from the automatic joint from the spinning to the spinning, from the spinning collective doffing transformation to the self-winding yarn library tray transformation, which has laid the foundation for textile enterprises to reduce labor.
Second, the intelligent transformation has achieved initial results
In the past 10 years, the intelligent level of the mainland textile industry has developed rapidly, and a number of full-process intelligent spinning model workshops have been created, such as Wuhan Yudahua, Jiangsu Dasheng, Wuxi Yimian, Weiqiao Textile, Shandong Huaxing, etc. The industry also generally recognizes that only by improving the intelligent level of domestic textile machinery and equipment can we accelerate the process of intelligent cotton textile enterprises.
2.1 Interdisciplinary cooperation helps textile intelligence
In recent years, a number of military-to-civilian enterprises in the mainland have used some military high-end technologies for textile intelligence, and a number of textile machinery-related enterprises have introduced high-tech talents from the Internet of Things. For example, Shanghai Hangshu Intelligent Technology Co., Ltd. has reached a cooperation agreement with well-known universities in the United Kingdom, established a European R&D center, and recruited some overseas scientific and technological talents with international vision and top R&D experience, including the chief engineer of Rolls-Royce Aero Engine in the United Kingdom, the R&D director of Siemens in Germany, and the R&D director of General Electric in the United States. They apply the industrial Internet platform to the textile field, and use communication terminals to connect various textile equipment from different manufacturers, different models, different networking ports and different communication protocols to a system platform, forming a LAN scheme that can be used in domestic intelligent textile workshops.
Zhengzhou Tianqi Automation System Co., Ltd., Qingdao Shuangqing Intelligent Technology Co., Ltd., Shandong Hurricane Automation Equipment Co., Ltd., etc. have also shown their skills in textile intelligent transformation. The TIS system developed by Zhengzhou Tianqi can complete the dynamic integration and processing of massive data at the bottom of the textile production process, analyze various production parameters and statistics in real time, and realize the all-round informatization of the textile production process, thereby greatly improving the production management efficiency of textile enterprises. Qingdao Shuangqing by Tsinghua University, Peking University, Beihang University and other colleges and universities of the doctor, master team, focus on building low consumption, high efficiency and high quality intelligent production system, the products have spread all over the country, among which the Qingyun series of foreign fiber machine double-sided detection innovation effect can be comparable to the international brand foreign fiber machine. Shandong Hurricane is a rising star in the industry, and the well-known domestic enterprise Inovance has established an electronic technology cotton spinning joint guarantee center, specializing in the research and development, manufacturing, sales and maintenance of textile automation products. These high-tech companies have intervened in the textile field, effectively resolved the shortcomings of traditional textile enterprises in the mainland in intelligent electronic technology, and have provided automation technical support, training and services for more than 600 textile enterprises, and upgraded textile equipment with the most professional technology.
2.2 Efforts of intelligent innovation of textile machinery enterprises
Intelligent technology is mainly reflected in the comprehensive application of computer technology, precision sensing technology and GPS positioning technology. To develop intelligent equipment, we must first have intelligent supporting software in the process of R&D, design and manufacturing. In recent years, mainland textile machinery enterprises have continuously carried out digital transformation, and applied manufacturing technology with digital technology, intelligent technology and network technology to the whole life cycle of product design, production, management and service, and there have been four major changes:
(1) Modern processing technology has reached a new level. Some textile machinery factories have introduced world-class intelligent mother machining equipment, such as pentahedral machining centers, horizontal machining centers, laser sheet metal cutting centers (precision cutting, bending, laser welding of sheet metal), CNC turret punches, CNC machine tools, CNC grinding machines, large-scale automatic spraying production lines, mold fixtures, injection molding, wear-resistant coatings, heat treatment and other equipment and technology applications, and continue to build a platform-based and modular R&D system.
(2) Apply CNC technology and intelligent technology to achieve product innovation. Some textile machinery enterprises also use intelligent equipment and technology in product innovation, such as the use of intelligent three-dimensional warehouse, tool warehouse, AGV and robot technology to establish automatic logistics between machining centers, with the help of CPS and IOT technology, the use of ERP/MES to achieve material resource planning, real-time production scheduling and online monitoring, and with the joint robot will be intelligent warehousing, automated logistics and automated processing units combined, and then through the support of information interconnection technology, to complete the overall planning of the digital factory.
(3) Adopt highly intelligent design software. For example, a large number of CAD, CAE and other software are used to improve the design ability through artificial intelligence algorithms, genetic algorithms, artificial intelligence deep learning object detection algorithms and other functions; AGV and RFID technology, RD technology, etc., expert systems, learning control, fuzzy logic control and neural networks with multi-layer perceptrons and other new technologies are developed, which also enables the control problems of complex systems to be solved, so that the design of intelligent control system tools is more reliable and powerful.
(4) Strengthen in-depth cooperation with enterprises in developed countries in Europe and the United States, and absorb advanced intelligent and mature technologies. For example, after the cooperation between AP Technology and RIETER of Switzerland, it has accepted many advanced concepts of "production process quality control management", and the yield rate and consistency of products have been greatly improved.
2.3 A brief review of the technological development of cotton spinning intelligent equipment
2.3.1 The journey from exhibit to product
At the 2018 Shanghai International Textile Machinery Exhibition, Kaiye Textile Machinery was the first to show the yarn magazine type self-winding automatic yarn loading system, which replaces manual yarn feeding and other operations through a series of complex programs and actions such as intelligent robots, including large and small head differentiation modules, pallet transportation logic control modules, visual monitoring and algorithm system modules, PLC control modules and various sensors, etc., after years of improvement and upgrading, the upper and middle tray conveying and feeding systems are optimized and integrated, and the bottom tray is used to convey yarn, which has been highly recognized by the market.
The speed of the intelligent packaging system of the yarn from the exhibits to the promotion and application is very fast, and so far there have been more than a dozen textile machinery factories have been put into production, and many cotton textile enterprises in the industry have listed it as a priority technical transformation project. Through data management and communication network technology, the intelligent packaging system of package yarn adopts the mode of immediate package and package, with the functions of online counterweight and online detection, and realizes the intelligent operation of online identification, weighing and screening, counterweight combination, packaging labeling, palletizing and other intelligent operations of multi-variety package yarn through data management and communication network technology, which improves the accuracy of package yarn detection, and can be connected with MES and ERP systems to realize the statistical and analysis functions of big data. In the package yarn intelligent packaging system, the appearance and quality of the package yarn accurate screening is one of the highest gold content of technology, Shuangqing intelligent to provide the Qingyun series of intelligent package yarn conveying and packaging system, it is said to be able to carry out a comprehensive check on the pass rate of the package, not only can use the air and ground dual-channel counterweight technology to achieve accurate counterweight, but also through the multiple visual detection system to achieve accurate scheduling of multiple varieties and the appearance of the yarn screening (including chrysanthemum yarn, step yarn, mesh yarn, oil stain, Dirty cylinders and other poorly formed yarns, and even the wrong yarn can be detected), which completely realizes the intelligent and unmanned operation requirements of package packaging.
2.3.2 Leapfrogging from Idea to Reality
(1) Changling Textile & Electric has developed a new generation of elite 52 electronic yarn clearer, which adopts DSP processing technology and has a high degree of intelligence, with automatic gain control, automatic zero point compensation, automatic yarn speed detection, automatic alarm and other functions. In addition to the functions of conventional channel yarn clearing, foreign fiber channel yarn clearing, yarn defect statistics, etc., yarn defects can also be graded online, which can provide basic data support for production management and process control.
(2) Jiangyin Kaiye's intelligent fine chain system based on Internet of Things technology solves the technical problems of line switching technology of overhead transportation track, machine material lifting and dumping, and enables the entire material system to realize the automatic transfer, tracking and distribution of spinning tube boxes, which can not only realize the group-to-group intelligent delivery of spinning tube boxes, but also comprehensively collect and process the location information and online waiting information of materials through Internet of Things tracking technology, so as to provide efficient material delivery for the workshop. The realization of intelligent production of spinning and winding machine and reverse traceability of bobbin quality provides guarantee and support.
(3) The intelligent process system of carding and carding under the development of White Shark card clothing can automatically complete the configuration and optimization of card clothing, change the process design and quality control means of the traditional passive mode, and can carry out intelligent and systematic process design of card clothing to meet the carding needs of different fibers, realize the maintenance-free card clothing under the premise of ensuring the quality of yarn, and realize the concept of flexible carding process. The need for efficiency.
(4) The "whole process intelligent cotton spinning complete set of equipment and system" developed by warp and weft textile machinery has been successfully applied to some high-end textile enterprises, covering the "three automatic" technology of combing (cotton roll unwinding, roll changing, Yarn all-electronic drafting technology to realize the digitization of drafting process adjustment; the whole process of intelligent complete logistics system (including: the use of AGV and RFID technology to realize the automatic conveying of the sliver drum between the carding machine and the drawing frame and the exchange of empty full cylinder, the automatic conveying and storage of the sliver between the comber and the unfinished drawing, the automatic conveying of the sliver between the drawing and the roving and the exchange of the empty full cylinder; the first mobile platform cache to change the drum mode, the use of RD technology to realize the scheduling of the conveying varieties; the whole process of intelligent return (silk) receiving and payment system, to achieve each processIntelligent sorting and collection and payment of each part of the flower (silk). ）
(5) The automatic bag unpacking machine of the straight reciprocating cotton grabber designed by the R&D team of Donghua University is mainly composed of a cotton bale conveyor, a hook and belt device, a tape cutting device, a waste belt collection device, a bag clamping device, a bag cutting device, a waste bag collection device, a first clamping car and a second clamping car. It solves the problems of high labor intensity and long time in the manual discharge process of cotton bales.
(6) TM19 high-speed intelligent draw frame realizes the functions of intelligent, digital electronic strip breaking, electronic tooth adjustment, self-leveling, online detection and monitoring, continuous automatic barrel change and mobile phone remote control. Its self-leveling system uses a dual-core processor and UQM non-contact in-line inspection system in hardware, which has a higher processing and execution speed, and can still ensure the stability of the weight of the output sliver when the feed sliver fluctuates by more than 38%.
(7) The mainland's original translational collective doffing system can meet the stable operation in a small space, adapt to the transformation of various models, and the doffing time can reach the level of similar long car colonies.
(8) The intelligent air-conditioning system realizes unmanned regulation and management, adopts fully digital data transmission and control mode, and accurately controls temperature and humidity, which can monitor and adjust the state of temperature and humidity in the workshop in real time.
(9) AMP integrated fully shielded metal probe and electrostatic compensation spark probe have intelligent self-test function, which can realize network remote control, which can provide a strong guarantee for the safe production of textile enterprises.
Third, the market demand for intelligence
3.1 The social effect of intelligent production in super-large enterprises
The mainland has about half of the world's spindles and production capacity, is the world's largest textile and garment production and exporter, yarn production scale and output in the world's first, there are a large number of more than one million spindles of spinning enterprises, such as Shandong Weiqiao entrepreneurship has reached 7 million spindles, Rainbow Textile Group 4.2 million spindles, Dezhou Hengfeng Group 3.2 million spindles, Taicang Litai Textile Group 3 million spindles, etc. Many of these super-large textile enterprises have been obtained through mergers, reorganizations and acquisitions, and some of the equipment is old, the degree of automation is low, and the intelligent transformation has a long way to go.
Such enterprises can carry out intelligent transformation in batches through the advantages of the group, such as the 50,000-spindle intelligent demonstration project to be built by Taicang Litai Silk Road, with only 4 people employed by 10,000 spindles, which has strong social effects and cost advantages. In addition, many super-large textile enterprises have the background of listed companies, can obtain the national key support policy guarantee, it is relatively easy to raise funds, and can be directly connected with the intelligent project of textile machinery enterprises for technological transformation, in order to reduce the cost of transformation and improve production efficiency.
3.2 Intelligent transformation needs and countermeasures of small and medium-sized textile enterprises
The equipment level of small and medium-sized textile enterprises is uneven, some enterprises still use the certificate of A-type, FA-type cotton spinning equipment in the last century, the equipment model is messy, the labor of 10,000 spindles is very high, and there is a strong power for intelligent transformation, but many small and medium-sized textile enterprises lack funds, and they have insufficient strength to transform, and hope that the state will introduce relevant financial support policies.
There are also some small and medium-sized textile enterprises with crowded equipment arrangements (such as cotton cleaning and carding car stalls are only about one meter), which brings great difficulty to intelligent transformation. Some textile machinery factories have combined with the actual situation of these enterprises in the mainland to develop the intelligent control system from plane layout to spatial layout, and become a design creativity with Chinese characteristics. For example, the small rolls are transported from the air to the combers, the roving and spinning bobbin yarns and bobbins are docked with the operating machine from the air through the automatic pipe management machine, and the bobbins of the automatic bobbin packing system are transported in the air throughout the whole process, etc., and the Internet of Things tracking technology, information comprehensive collection and processing technology, reverse traceability technology, etc., are widely used to make production management more reliable and seamless and efficient operation.
At present, the mainland textile enterprises operating "difficult to recruit, difficult to retain, difficult to employ" has become a reality that cannot be denied, the only way to solve the "three difficulties" problem is to carry out intelligent transformation in stages, in the process and equipment that employs more people and can not retain people, to accelerate the transformation process.
The key to the information transformation of small and medium-sized textile enterprises lies in opening up the digital information chain of the stand-alone machine within the enterprise. For example, Sichuan Zero Point Automation System Co., Ltd. can be transformed by information technology to network each stand-alone logic controller for cleaning, combing, merging, coarseness, fineness and networking, collect production information and send it to the special wireless module, and then send the data information to the ERP system through wireless to complete the ERP resource management system. Through core technologies such as big data, cloud computing, IoT communication, and 5G + industrial Internet, Haier Kaos can open up the data chain of multiple management systems within the enterprise, and realize refined management through big data analysis of the system, and use 5G data transmission and intelligent management cloud platform and other technologies to realize the intelligence and digitalization of operation, equipment and manufacturing, so that the enterprise can become a "black light factory" led by intelligent manufacturing and supported by information technology.
3.3 Resolve the concerns of intelligent transformation
In general, the higher the degree of automation of the cotton spinning production equipment, the higher the energy consumption per unit of production time. Suzhou Zhenlun's experience is worth learning from, they adhere to the concept of green, low-carbon and high-quality development, eliminate high-energy-consuming equipment, improve efficiency through intelligent equipment upgrades, introduce world-class intelligent spinning equipment, introduce new energy-saving technologies, use the roof of the plant for photovoltaic power generation, through energy conservation and emission reduction, process improvement, fine management and other means, the use of rare earth permanent magnet motor +Frequency conversion technology transforms the equipment, carries out fine maintenance of the equipment and reduces the load to reduce energy consumption.
Fourth, the intelligent transformation of textile enterprises
Technical hurdles to overcome
4.1 Intelligent transformation of color spinning enterprises
The batch of dyed spinning yarn is small, the variety changes frequently, the employment of the color spinning enterprise is more than 50% higher than the white spinning enterprise with the same equipment, from the raw material mixing, pretreatment, packing, precise control of the blending ratio, to the combing and thickness of the various processes of the variety transformation, quality control, etc., there is no mature intelligent equipment, it is necessary to develop intelligent equipment suitable for color spinning.
4.2 The automatic bag unpacking machine needs to be perfected
At present, the research and development of cotton bag automatic bag unpacking machine is only suitable for straight reciprocating cotton grabbing machine, and the mechanism is complex, the cost is high, the payback period is more than 4 years, and it is difficult to promote it in a large area. The disc type cotton grabber is suitable for the production of small batch varieties, and the product transformation is more convenient, so it is necessary to develop a more flexible and mobile automatic bag unpacking machine.
4.3 The intellectualization of roving in the spinning workshop
The spinning process needs to change the roving, especially the frequency of changing the roving is higher when the production of the middle and coarse yarn, and the current coarse and fine coupling system can send the roving to the relevant position through the rail, but the replacement of the roving still needs to be carried out manually. If the automatic replacement of roving and splices can be realized, a lot of labor can be saved, and more importantly, the goal of unmanned workshop can be truly realized.
4.4 Shorten the payback period
An important factor restricting the intelligent development of spinning equipment is the problem of cost performance, that is, how to realize the cost of intelligent spinning equipment and shorten the payback period. From Huaxing's experience, to improve the profitability of intelligent factories as much as possible, lies in the lean and automated production and manufacturing, the digitization and efficiency of business processing, the modelization and standardization of operation and management, the formation of integrated applications of large platforms, and the construction of digital collaboration platforms to improve production efficiency and reduce production costs. At present, Huaxing Intelligent Spinning can save 80% of labor (15 people for 10,000 spindles), increase production efficiency by 20%, increase energy utilization by 12%, shorten product delivery cycle by 30%, increase profit margin by 50%, reduce operating costs by 20%, and reduce finished product inventory and raw material inventory by 30%.
V. Conclusion
In order to improve the labor productivity of the whole industry, accelerate the technological progress of the industry, and promote automation, informatization and intelligent intelligent manufacturing, it has become the only way to enhance the competitiveness of the cotton textile industry in the mainland.
Source: Miao Dingshu Suzhou Textile Engineering Society
Editor: China Yarn Network New Media Team
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